Metal Cutting

Material removal through cutting, turning, milling, drilling, grinding, tapping and more using machinery such as laser cutting systems, plasma cutting systems, oxyfuel cutting systems, milling machines, drill presses, lathes, horizontal machining centers, vertical machining centers, turning centers, multitasking machines, electrical discharge machines and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), automation and robotics.

3D, Robots, Big Data and a Few Memories

Looking back at IMTS 2014, we all got a peek into the future of additive manufacturing and process chains, plus a few exciting concepts that are going to find their way into the operation of your shop very soon.
Experts
Automation/Robotics

Intelligent Factories: The Fourth Industrial Revolution

The biggest challenge for intelligent metalworking shops is implementing the correct individualized manufacturing systems on the software side that can fit their unique needs and provide competitive advantages.
A new era of highly efficient, flexible and customizable mass production requires software and analytical systems that turn the deluge of data produced by intelligent factories into useful and valuable information.
CAD/CAM Software

Mission Accomplished

Robotic metal polishing; Mico Industries.
Thanks to SolidCAM iMachining, cycle times are down 50 percent, tool life is up 40 percent, and Mico Industries is creating dies, weld fixtures and check fixtures without compromise.
Drilling Machines

Making Natural Gas Clean with a “Hole” Lot of Pressure

A pressure vessel in the mid-fabrication stages. The pressure vessels Mueller Environmental manufacturers measure anywhere from 4 ft to 8 ft in diameter and are made from ½ in to 3 1/2 in thick 5617 rolled steel plate. The diameter and material thickness depends upon the pressure the vessel must withstand. Sometimes pressures can reach as high as 3,000 psi.
Using a modified HMD915 magnetic drill and Industrial Series of Rotabroach Cutters from Hougen enabled Mueller Environmental to cost-effectively develop a patented new system for cleaning natural gas.
Gear Cutting Machines

Gear Production: Higher Speed, Closer Precision

The accuracy of the Fast Gear Alignment function eliminates the need to acquire acoustic signatures during dressing or grinding. Aligning a grinding wheel with a 180 mm diameter gear with 71 helical teeth takes just 0.5 of a second – without any need to acquire acoustic signatures or make manual adjustments. 
Automated threaded wheel grinding on gear production machines has now been boosted by an order of magnitude with increased machining accuracy to DIN class 3.
Grinding Machines

Gear Hobbers and Control Migration

All seven axes on the 400H Series II gear hobber, including the 560 Nm work piece spindle motor, are controlled by NUMDrive C servo drives and a Flexium 68 CNC system. (first view)
This is the story of how Bourn & Koch upgraded its older gear hobbers to advanced CNC systems to machine large bull and cluster gears, worms, shafts, splines and pinions for the defense and aerospace, oil/gas drilling, mining, heavy equipment and power generation industries.
Honing Machines

A Chip Off the Old Block

Dart produces about 16,000 cylinder heads per year.
Dart masters the "peaks and valleys" of custom engine block production with an advanced American-made Sunnen SV-20 flexible honing system that uses programmable control to replicate “best” engine parameters and produce expert results with minimal operator expertise.
Horizontal Machining Centers

High Speed Horizontal Machining of Largest Parts in Class

The HMC500 can reach cutting speeds of 15,000 rpm in a mere 1.7 seconds (with 50 hp) for faster machining of a variety of tough materials, including 1018 steel.
The HMC500 from OKK is built for speed and faster cycle times, with exceptionally fast automatic pallet and tool changers and the ability to complete deep boring operations without rotating the pallet.
Laser Cutting

Micromachining: No More Constraints

Prototyping time for new nozzle designs is reduced from weeks in the machine shop to 24 hours with the R-Drill, dramatically accelerating design optimization and time to market. The R-Drill reduces drilling time by approximately 30 percent while increasing yield to nearly 100 percent, with no need for expensive post-processing to correct HAZ damage.
The latest femtosecond laser technology from Raydiance can reduce cost per part by 20 percent to 50 percent and reduce product design, prototyping and development from months to as little as 24 hours.
Lathes

Hard Thread Turning Shortens The Process Chain

Figure 1. High rigidity allows higher process forces: Hembrug turning machines are especially suitable for high-precision hard turning.
High precision hard turning techniques are enjoying ever greater popularity in the metal processing industry. By shortening cycle times and increasing flexibility, high precision hard turning has advantages over grinding in particular when it comes to processing complicated parts such as spindle nuts or threaded spindles in the hard state.
Machine Controls

Producing Turbine Blades with the Highest Precision

Manufacturing precise free-form surfaces for turbine blades demands the highest performance from the CNC. The excellent block-cycle times of the Sinumerik 840D sl and its look-ahead function improved as part of the new Advanced Surface motion control that plays a significant role here. (first view)
This shop shows how to strike an ideal balance between the powerful roughing and ultra-precise finishing that is required to make turbine blades by building a five-axis turn-mill center that combines robust machine construction with high-quality drive and control engineering. 
Milling Machines

Boring Mill Fuels Energy Sector Expansion for Machine Shop

The dual-pallet, rotary table Giddings & Lewis MC 1600 horizontal boring mill (HBM) from Fives is designed for multi-axis contour milling, precision boring, drilling and tapping. It will produce a variety of large parts for Milwaukee Machine Works, including wind turbine gearbox housings and fluid end manifolds for the oil/gas industry.
Milwaukee Machine Works expands its energy sector business into wind turbine gearbox housings, fluid end manifolds for the oil/gas industry, and other oversized components up to 10 ft long and weighing up to 7,000 lb with a new large capacity dual-pallet Giddings & Lewis MC 1600 from Fives.
Multitasking Machines

Shoot from the Hip

Custom shoulder implant parts on the NTX 2000 turn-mill center, which has opened up new possibilities for parts that previously required at least two operations. Rasp handles that were previously contracted outside will become some of the first components loaded on the new machine.
This orthopedics manufacturer achieves one hit machining in an automated lights-out environment using advanced turn-mill machines that take their custom implants for coated hip replacement to a whole new efficiency.
Ram EDM Machines

A Hole New Game: Precision EDM Holemaking Goes Smaller, Deeper and Faster

Technically advanced EDM drill systems merge hole popper technology with die-sinker digital generator technology for more precise spark control that essentially puts the holemaking accuracy in the technological hands of the machine tool.
While hole-popper systems are quite capable of generating very small accurate holes with good surface quality, advanced EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality.
Software

How to Simplify Complex Geometry Tool Repair

By enabling the entry point of the grinding wheel to follow the corner radius of the cutting edge, the software now facilitates the grinding of a defined rake angle on complex body forms and on cutting edges which pass from the body of the tool to its tip – a task that was previously extremely difficult to achieve.
A new release of NUMROTO tool grinding software meets the growing challenges of grinding and servicing new generations of complex geometry drills and end mills.
Vertical Machining Centers

Advanced Machining Allows Subsea Valves To Handle the Pressure

Operating a DMG / Mori Seiki NL2500 at BEL Valves.
BEL Valves uses a variety of DMG / MORI SEIKI machine tools to meet its paramount need for reliability during production. 
Wire EDM Machines

Wire Changing EDM Proves Big in Micro Tooling Production

Mike (right) and Eric Blackwell of Scenic Tool and Stamping rely on a CUT 2000 wire EDM from GF AgieCharmilles that uses new third-generation twin-head automatic wire changing to easily achieve surface finishes of .2 Ra. (Click on photo to enlarge it)
As consumer products continue to shrink in size, die shops such as Scenic Tool and Stamping face the challenge of developing highly intricate tooling for stamping the tiny components that make up miniature merchandise. As a result, an increasing number of these shops are incorporating high-precision wire EDMs like the Cut 2000 from GF AgieCharmilles that provide automatic wire-changing capability. uses the to easily switch wires of different sizes and materials.
Metal Cutting: Products

Efficient Bar Machining of Complex Parts

The bar capacity of the main spindle on the SPRINT 20|5 is Ø 20 mm / 0.8 in. The counter spindle can be optionally equipped for shaft unloading of workpieces measuring Ø 20 x 600 mm / 0.8 x 23.6 in. The main spindle is also equipped with a C-axis for the machining of complex operations. The counter spindle is equipped with a C-axis when combined with the optional driven tools for rear-sided machining. 
The SPRINT 20|5 from DMG MORI is ideal for the high volume production of simple to medium complexity parts machined from bar.

Mill, Drill, Grind Aerospace Parts on One Machine

The unique two-axis Programmable Coolant Nozzle (PCN) handles variations in wheel diameter and changes in cutting direction while maintaining ideal coolant flushing conditions. It also allows for intermittent NC-controlled, electrically powered rotary dressing that trues the wheel to reestablish profile geometry on the cutting wheel. 
The flexible G7 Grinder 5-axis horizontal machining center from Makino grinds, drills and mills aerospace blades, vanes, turbine disks and other complex components.

Angle Grinders Maximize Material Removal

The key features in the 1660 and 2260 angle grinders include dual auxiliary handle positions, reversible throttle handle and interchangeable guards that allow for versatility to fit any application.
The 1660 and 2260 Angle Grinders from Cleco Tools have a streamlined angle head and all metal housing for ultimate ruggedness that minimizes shop downtime, enhances productivity and increases the bottom line.